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SL-IV 50 PLUS Manual

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SL-IV 50 PLUS Manual STREAMLINE HIGH-PRESSURE WATERJET PUMP OPERATION and SERVICE MANUAL STREAMLINE SL-IV 50 STREAMLINE SL-IV 50 400 V / 3 / 50 Hz Manual No. 05146311 Rev. 3 Original: July 2003 CPN-Nr.: 80800-GB-08 NOTICE This document contains subject matter in which KMT Waterjet Systems Company has proprietary rights. Recipients of this document shall not duplicate, use, or disclose information contained herein, in whole or in part, for other than the purpose for which this manual was provided. KMT Waterjet Systems believes the information described in this manual to be accurate and reliable. Much care has been taken in its preparation, however, the Company cannot accept any responsibility, financial or otherwise, for any consequences arising out of the use of this material. The information contained herein is subject to change, and revisions may be issued to advise of such changes and/or additions. KMT Waterjet Systems 2004 KMT Waterjet Systems Wasserstrahl-Schneidetechnik GmbH Auf der Laukert 11 D – 61231 Bad Nauheim, Germany Tel. +49 (0) 60 32 – 997 0 Fax: +49 (0) 60 32 – 997 270 E-Mail: [email protected] 01/2004 01/2004 SECTION 0 TABLE OF CONTENTS TABLE OF CONTENTS 1 INTRODUCTION (1) 1-1 1.1 Description 1-1 1.1.1 Features 1-3 1.2 Functional Description 1-3 1.2.1 Functional Features 1-3 1.3 Worldwide Product Support 1-5 1.3.1 GOLD- und SILVER-Service - Cost-Calculation Security 1-5 1.3.2 Service Department 1-5 1.3.3 Parts Support 1-6 1.3.4 Questionnaire 1-6 1.4 Safety 1-9 1.4.1 Labels and Abbreviations 1-9 1.4.2 Safety Procedures 1-11 1.4.3 High-Pressure (HP) Piping Safety 1-13 1.4.4 Emergency Medical Treatment 1-14 2 INSTALLATION (2) 2-1 2.1 Installation Overview 2-1 2.1.1 Buyer Obligations 2-1 2.1.2 Seller Obligations 2-1 2.2 Installation Requirements (Utilities) 2-2 2.2.1 Equipment Location/Environment 2-2 2.2.2 Service Connections 2-3 2.2.3 Tools and Equipment 2-5 2.2.3.1 HP Tube Coning and Threading Procedures 2-5 3 OPERATION (3) 3-1 4 MAINTENANCE (4) 4-1 4.1 Scheduled Maintenance 4-3 4.2 General Maintenance 4-4 5 TROUBLESHOOTING (5) 5-1 5.1 TROUBLESHOOTING - Electrical 5-1 5.2 TROUBLESHOOTING – HP WATER 5-3 5.3 TROUBLESHOOTING – LP WATER 5-5 5.4 SPECIAL PROCEDURE—HP WATER CHECK VALVE TROUBLESHOOTING 5-6 5.4.1 HP Check Valve Troubleshooting 5-6 5.4.2 OUTLET HP Check Valve – Troubleshooting 5-6 5.4.3 INLET Cutting Water Check Valve – Troubleshooting 5-7 6 LOW PRESSURE WATER SYSTEM - FEATURES (6) 6-1 6.1 Oil Cooling Water Supply 6-1 6.2 Cutting Water Supply 6-1 6.2.1 Normal Operating Condition 6-2 6.2.2 Operation 6-2 6.2.3 Booster Pump 6-5 01/2004 1 SECTION 0 TABLE OF CONTENTS 6.2.4 Low Pressure System Protection 6-5 6.3 Maintenance Overview 6-6 6.3.1 Water Filter Service 6-6 6.3.2 Booster Pump 6-6 7 HIGH-PRESSURE (HP) WATER (7) 7-1 7.1 Components 7-1 7.2 Intensifier Disassembly and Reassembly 7-1 7.2.1 HP & LP Water Piping 7-3 7.2.2 HP Cylinder “Jug” (HP Cyl., Sealing Head, Flanges, & Studs)—Disassembly / Re- assembly 7-4 7.2.3 Stud Nuts and End Flange, Sealing Head—Disassembly / Re-assembly 7-5 7.2.4 HP Plunger Seal Service-- Disassembly / Re-assembly 7-7 7.2.5 Plunger and Hydraulic Cartridge Removal and Installation 7-11 7.2.6 Hydraulic Cylinder Head and Piston—Removal / Re-Installation 7-12 7.3 Intensifier Subassemblies Inspection and Repair 7-14 7.3.1 Discharge HP Check Valve 7-14 7.3.2 Inlet Check Valve 7-15 7.3.3 Sealing Head 7-16 7.3.4 HP Cylinder 7-17 7.3.5 Plunger 7-18 7.3.6 Hydraulic Piston 7-19 7.3.7 Hydraulic Cylinder 7-22 7.4 HP Dump Valve 7-23 7.5 HP Attenuator 7-23 8 ELECTRICAL SYSTEM - FEATURES (8) 8-1 8.1 Electrical Overview 8-1 8.1.1 Motor Starter Circuit 8-1 8.1.2 Control Circuits and Logic 8-1 8.1.3 Operation 8-3 8.2 Maintenance Overview 8-5 8.2.1 Proximity Switch Service 8-6 8.2.2 Optical Relay Switch Service 8-7 9 HYDRAULIC SYSTEM - FEATURES (9) 9-1 9.1.1 Components 9-2 9.2 Operation 9-2 9.2.1 Hydraulic Pressure Adjustment 9-3 9.2.2 Hydraulic System Pressure Protection 9-3 9.3 Motor / Hydraulic Service Maintenance 9-3 9.3.1 Motor Service 9-4 9.3.2 Manifold Service 9-4 9.3.3 Motor/ Pump Coupling – Spline Lubrication— 9-5 10 RECIRCULATION SYSTEM - FEATURES (10) 10-1 10.1 Components 10-1 10.2 Operation 10-1 10.3 System Pressure Protection 10-2 01/2004 2 SECTION 0 TABLE OF CONTENTS 10.4 Maintenance Overview 10-3 11 SPECIFICATIONS (11) 11-1 11.1 Equipment Specifications 11-1 11.2 Torque Specifications 11-3 11.3 Cutting Water Specifications 11-4 12 SPARE PARTS CATALOGUE (12) 12-1 12.1 General 12-2 12.2 Part Nomenclature 12-2 01/2004 3 SECTION 0 TABLE OF CONTENTS 01/2004 4 SECTION 1 INTRODUCTION Section 1 INTRODUCTION 1 Introduction (1) The Streamline™ IV / PLUS (SL-IV / PLUS) waterjet pump maintains the level of component reliability and the ease of installation and maintenance that has made KMT Waterjet Streamline waterjet pumps the standard of the industry for both water and Hydrobrasive™ applications. The SL-IV / PLUS waterjet pump provides output water pressures up to 4,100 bar (60,000 psi) for ultrahigh-pressure waterjet cutting, hydrobrasive cutting, cleaning, surface preparation, etc. This manual provides information for installation, operation, and maintenance of the SL-IV / PLUS waterjet pump. 1.1 Description The SL-IV / PLUS waterjet pump is a self-contained functional unit. The major assemblies within the SL-IV / PLUS intensifier are single (or optional redundant) high-pressure intensification assemblies, single or dual high- pressure attenuator(s), a motor and hydraulic pump assembly, an oil cooling/filtration system, a low pressure water booster pump with low pressure water filtration, a fail-safe high-pressure venting valve, and an integrated NEMA 12 electrical control enclosure. .jpg Letter Connection U Cutting Water OUT ...3/8” HP V Plant Air ...................¼” NPT W Cooling Water IN.......½” NPT X Cooling Water OUT ...½” NPT Y Cutting Water IN.......½” NPT Z Drain........................½” NPT 01/2004 1 - 1 SECTION 1 INTRODUCTION NOTE KMT Waterjet Systems recommends approx. 950 mm / 36” minimum clearance around intensifier for maintenance. Dimension Letter mm inch A 1.721 67,75 B 914 36,00 C 1.453 57,19 F 914 36,00 G 812 32,00 H 419 16,50 I 343 13,50 K 267 10,50 L 191 7,50 M 1.092 43,00 N 330 13,00 The SL-IV / PLUS waterjet pump is enclosed in a frame 67.75” (172 cm) long, 36.0” (91 cm) wide and 57.19” (145 cm) tall. The high-pressure intensification assembly is mounted on a drip pan on the frame top at a convenient height for performing routine maintenance. All components requiring routine maintenance are easily accessible through self-levitating hinged transparent covers or removable protective panels covering the sides of the lower frame. The high-pressure intensification assembly can be easily and quickly removed from the intensifier base if deemed desirable or necessary for maintenance. 01/2004 1 - 2 SECTION 1 INTRODUCTION 1.1.1 Features • Variable displacement, pressure compensated axial piston hydraulic pump. • Inlet water pressure booster pump and filtration system with 10-micron high capacity filter. • High efficiency oil-to-water heat exchanger and cartridge oil filter in an oil circulation pump circuit separate from the main hydraulic pump circuit. • Thermostatically controlled water-cooling system for optimum hydraulic oil temperature stability. • Integrated electrical controls include a standard wye-delta motor starter to minimize motor inrush current at startup. • High-pressure safety dump valve. • Dual pressure compensators on the main hydraulic pump allow manual or program controlled selection of two different output pressures. • Optional electronically controlled continuously variable hydraulic pressure control may be integrated into the host CNC unit for real-time pressure control. • TUV approved high-pressure attenuator for smooth high-pressure water delivery. • TUV approved pre-set hydraulic relief valve eliminates the need for rupture disc overpressure protection. • Microprocessor control with diagnostic capability and multi-language touch screen operator interface. • Cutting water solenoid-operated shutoff valve. • Inlet water pressure and booster pressure switches insure that there is adequate supply water pressure to the SL-IV / PLUS high-pressure intensification assembly to prevent water starvation damage. • Separate water and oil drip pans for cleanliness. • Remote control electrical interface connector port. • Remote diagnostic communication option. 1.2 Functional Description The HP intensification assembly uses a hydraulically driven piston operating in electrically reversed reciprocating mode, coupled at both ends to high-pressure intensification cylinders. The HP intensification cylinders extrude high-pressure water alternately, while the HP attenuator minimizes fluctuations in the output water signal. The intensification ratio is 20:1 with maximum hydraulic pressure set at 3,100 psi. 1.2.1 Functional Features • 4,150 bar (60,000 psi) operating pressure • Electronic reversing 01/2004 1 - 3 SECTION 1 INTRODUCTION • 24vdc control logic • Built-in high-pressure water leak detection diagnostics • Standard dual pressure control facilitates hole piercing and kiss cut applications • Exclusive long, slow plunger stroke • Cartridge type hydraulic seals • Low pressure water booster pump and filtration • Reduced cooling water requirements • Choice of English, German, Spanish, French, Swedish and Italian readouts as standard • Meets CE requirements 01/2004 1 - 4 SECTION 1 INTRODUCTION 1.3 Worldwide Product Support The KMT Waterjet Service Department serves the customer, by providing: Supervision of equipment installation, start up, and training for the number of days specified in the quotation, and per approved project.
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